Ultrasound device for precise tissue sealing and blade-less cutting

ABSTRACT

An electrosurgical instrument for sealing and cutting tissue is provided. The instrument includes a housing having a plurality of transducers included therein and a waveguide coupled to and extending from the housing. An end effector assembly disposed at a distal end of the waveguide includes a pair of opposing jaw members, where at least one of the jaw members includes a transducer. The transducer is configured to receive an acoustic signal from the plurality of transducers in the housing.

BACKGROUND

1. Technical Field

The present disclosure is directed to an electrosurgical apparatus. More specifically, the present disclosure is directed to an electrosurgical apparatus that employs ultrasound for precise tissue sealing and blade-less cutting.

2. Background of the Related Art

Open or endoscopic electrosurgical forceps utilize both mechanical clamping action and electrical energy to effect hemostasis. The electrode of each opposing jaw member is charged to a different electric potential such that when the jaw members grasp tissue, electrical energy can be selectively transferred through the tissue. A surgeon can cauterize, coagulate/desiccate and/or simply reduce or slow bleeding, by controlling the intensity, frequency and duration of the electrosurgical energy applied between the electrodes and through the tissue.

Certain surgical procedures require more than simply cauterizing tissue and rely on the combination of clamping pressure, electrosurgical energy and gap distance to “seal” tissue, vessels and certain vascular bundles. More particularly, vessel sealing or tissue sealing utilizes a unique combination of radiofrequency (RF) energy, clamping pressure and precise control of gap distance (i.e., distance between opposing jaw members when closed about tissue) to effectively seal or fuse tissue between two opposing jaw members or sealing plates. Vessel or tissue sealing is more than “cauterization”, which involves the use of heat to destroy tissue (also called “diathermy” or “electrodiathermy”). Vessel sealing is also more than “coagulation”, which is the process of desiccating tissue wherein the tissue cells are ruptured and dried, “Vessel sealing” is defined as the process of liquefying the collagen, elastin and ground substances in the tissue so that the tissue reforms into a fused mass with significantly-reduced demarcation between the opposing tissue structures.

Many electrosurgical instruments include a cutting member for cutting sealed tissue. Existing methods involve the use mechanical or electrical cutting actions. For example, a knife may be included in an electrosurgical instrument. Alternatively, an electrode may be used to apply electrical energy in the region. The use of a knife or electrode may be disadvantageous because it may lead to uncontrollable wide thermal spread.

Ultrasound may also be used for sealing and cutting tissue. One such example is an ultrasonic scalpel that uses an acoustic transducer operating in a longitudinal mode at 55 KHz located remotely from tissue. Energy is amplified and transmitted to the blade system by an acoustic mount coupled to the housing of a hand piece. Mechanical energy propagates in a metallic rod of the blade system having jaw members at a distal end thereof. However, such a device can not concentrate ultrasound waves in a precise spot and, as a result, may have an even larger thermal spread then many radio frequency electrosurgical devices.

SUMMARY

In an embodiment of the present disclosure, an electrosurgical instrument for sealing and cutting tissue is provided. The instrument includes a housing having a plurality of transducers included therein and a waveguide coupled to and extending from the housing. An end effector assembly disposed at a distal end of the waveguide includes a pair of opposing jaw members, where at least one of the jaw members includes a transducer. The transducer is configured to receive an acoustic signal from the plurality of transducers in the housing.

The transducer in the end effector assembly is coupled to a generator and the transducer converts the received acoustic signal into an electrical signal that is transmitted to the generator. The generator receives the electrical signal and outputs a time-reversed signal to the plurality of transducers in the housing. The plurality of transducers in the housing transmits the time-reversed signal to the transducer in the end effector assembly through the waveguide.

The transducer in the end effector assembly may be a piezoceramic transducer that is formed beneath a sealing surface of the at least one jaw member, as an integral part of a sealing surface of the at least one jaw member or formed as a stop member on top of a sealing surface of the at least one jaw member.

In another embodiment of the present disclosure, an electrosurgical system is provided. The system includes an electrosurgical instrument having a housing with a plurality of transducers included therein and a waveguide coupled to and extending from the housing. An end effector assembly disposed at a distal end of the waveguide includes a pair of opposing jaw members, where at least one of the jaw members includes a transducer. The transducer is configured to receive an acoustic signal from the plurality of transducers in the housing. The system also includes a generator coupled to the plurality of transducers in the housing and the transducer in the end effector assembly.

The transducer in the end effector assembly converts the received acoustic signal from the plurality of transducers in the housing into an electrical signal that is transmitted to the generator. The generator includes a phase/time reversal unit configured to receive the electrical signal from the transducer in the end effector assembly and output a reversed electrical signal to the plurality of transducers in the housing.

The transducer in the end effector assembly may be a piezoceramic transducer that is formed beneath a sealing surface of the at least one jaw member, as an integral part of a sealing surface of the at least one jaw member or formed as a stop member on top of a sealing surface of the at least one jaw member.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features, and advantages of the present disclosure will become more apparent in light of the following detailed description when taken in conjunction with the accompanying drawings in which:

FIG. 1A is a right, perspective view of an electrosurgical instrument according to an embodiment of the present disclosure;

FIG. 1B is an internal view of the electrosurgical instrument of FIG. 1A;

FIG. 2 is a schematic diagram of the electrosurgical instrument of FIG. 1A;

FIG. 3 is a schematic diagram of the electrosurgical instrument of FIG. 1A;

FIG. 4A-4C are perspective views of the end effector assemblies according to embodiments of the present disclosure;

FIG. 5 is a graph depicting an electrical signal at the end effector assembly according to an embodiment of the present disclosure;

FIG. 6 is a graph depicting the electrical signal of FIG. 5 after processing by the phase/time reversal block according to an embodiment of the present disclosure; and

FIG. 7 is a graph depicting the resulting signal at a spot according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

Particular embodiments of the present disclosure are described hereinbelow with reference to the accompanying drawings; however, the disclosed embodiments are merely examples of the disclosure and may be embodied in various forms. Well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary detail. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure in virtually any appropriately detailed structure.

Like reference numerals may refer to similar or identical elements throughout the description of the figures. As shown in the drawings and described throughout the following description, as is traditional when referring to relative positioning on a surgical instrument, the term “proximal” refers to the end of the apparatus that is closer to the user and the term “distal” refers to the end of the apparatus that is farther away from the user. The term “clinician” refers to any medical professional (e.g., doctor, surgeon, nurse, or the like) performing a medical procedure involving the use of embodiments described herein.

Electromagnetic energy is generally classified by increasing energy or decreasing wavelength into radio waves, microwaves, infrared, visible light, ultraviolet, X-rays and gamma-rays. As used herein, the term “microwave” generally refers to electromagnetic waves in the frequency range of 300 megahertz (MHz) (3×10⁸ cycles/second) to 300 gigahertz (GHz) (3×10¹¹ cycles/second). As used herein, the term “RF” generally refers to electromagnetic waves having a lower frequency than microwaves. As used herein, the term “ultrasound” generally refers to cyclic sound pressure with a frequency greater than the upper limit of human hearing. The terms “tissue” and “vessel” may be used interchangeably since it is believed that the present disclosure may be employed to seal and cut tissue or seal and cut vessels utilizing the same principles described herein.

FIG. 1 depicts a bipolar forceps 10 for use with various endoscopic surgical procedures and generally includes a housing 20, a handle assembly 30, a rotating assembly 80, a switch assembly 70 and an end effector assembly 105 having opposing jaw members 110 and 120 that mutually cooperate to grasp, seal and/or divide tubular vessels and vascular tissue. The jaw members 110 and 120 are connected about pivot pin 19, which allows the jaw members 110 and 120 to pivot relative to one another from the first to second positions for treating tissue.

Forceps 10 may be a unilateral or bilateral forceps that includes a waveguide 12 that has a distal end 16 configured to mechanically engage the end effector assembly 105 and a proximal end 14 that mechanically engages the housing 20. The waveguide 12 may include one or more known mechanically-engaging components that are designed to securely receive and engage the end effector assembly 105 such that the jaw members 110 and 120 are pivotable relative to one another to engage and grasp tissue therebetween. The proximal end 14 of waveguide 12 mechanically engages the rotating assembly 80 to facilitate rotation of the end effector assembly 105.

Handle assembly 30 includes a fixed handle 50 and a movable handle 40. Fixed handle 50 is integrally associated with housing 20 and handle 40 is movable relative to fixed handle 50 to actuate the opposing jaw members 110 and 120 of the end effector assembly 105. Movable handle 40 and switch assembly 70 are of unitary construction and are operatively connected to the housing 20 and the fixed handle 50 during the assembly process. Housing 20 is constructed from two component halves 20 a and 20 b that are assembled about the proximal end of waveguide 12 during assembly. Switch assembly 70 is configured to selectively provide ultrasound to the end effector assembly 105 via waveguide 12 as will be described in more detail below.

As mentioned above, end effector assembly 105 is attached to the distal end 16 of waveguide 12 and includes the opposing jaw members 110 and 120. Movable handle 40 of handle assembly 30 imparts movement of the jaw members 110 and 120 from an open position wherein the jaw members 110 and 120 are disposed in spaced relation relative to one another, to a clamping or closed position wherein the jaw members 110 and 120 cooperate to grasp tissue therebetween.

FIG. 1B depicts an internal view of housing 20 according to an embodiment of the present disclosure. As shown in FIG. 1B, housing 20 includes a number of transducers 130 that are electrically coupled to generator 500 via conduit 210. Alternatively, generator 500 may be incorporated into housing 20. A battery pack (not shown) may also be included in housing 20 to supply energy to a generator disposed in housing 20. Although only three (3) transducers are depicted, any number of transducers may be used with out departing from the scope of the present disclosure. Transducers 130 are acoustical transducers that convert electrical energy into acoustic waves. Transducer 130 may be a piezoelectric transducer that includes a piezoelectric ceramic element that creates and distributes ultrasonic sound waves. When a voltage is applied from generator 500 to transducer 130, piezoelectric material within transducer 130 will bend, stretch, or otherwise deform. This deformation is usually very slight and proportional to the voltage applied, and, as such, offers a method of precision movement on the micro scale. The voltage generated by a piezoelectric transducer can be quite high, often in the thousands of volts, but is brief, occurring only when the material is initially deformed. The piezoelectric material may include crystals (e.g., quartz or topaz) or polymers or ceramics that show piezoelectric properties.

As shown in FIG. 2, transducers 130 generate acoustic waves, which propagate through the waveguide 12 to miniature piezoceramic probes 140 in end effector assembly 140 as shown in FIG. 3. Waveguide 12 is a solid metallic piece, e.g., aluminum, that transmits acoustic waves therethrough. The waveguide 12 does not vibrate. The acoustic waves undergo multiple reflections resulting in an electrical signal registered at the output of probe 140 as shown in FIG. 5.

FIG. 3 depicts a schematic diagram of the electrosurgical system according to an embodiment of the present disclosure. As shown in FIG. 3, the system 300 includes a generator 500. Generator 500 can perform ultrasonic electrosurgical procedures and may include a plurality of outputs for interfacing with various electrosurgical instruments (e.g., a monopolar active electrode, return electrode, bipolar jaw members, footswitch, ultrasonic horn, etc.). Further, generator 500 includes electronic circuitry configured for generating power specifically suited for various electrosurgical modes (e.g., cutting, blending, division, fragmenting, coagulating etc.) and procedures. Generator 500 includes suitable input controls (e.g., buttons, activators, switches, touch screen, etc.) for controlling the generator 500. In addition, the generator 500 may include one or more display screens for providing the user with variety of output information (e.g., intensity settings, treatment complete indicators, etc.). The controls allow the user to adjust power of the energy, waveform, as well as the level of maximum are energy allowed that varies depending on desired tissue effects and other parameters to achieve the desired waveform suitable for a particular task (e.g., coagulating, tissue sealing, intensity setting, etc.). In another embodiment, generator 500 may be included in fixed handle 50 of handle assembly 30.

Generator 500 provides an electrical signal to transducers 130, which, in turn, generate acoustic waves or signals that are propagated through waveguide 12 to probes 140 in end effector assembly 105. Probes 140 are piezoceramic transducers that receive acoustic waves from transducers 130 and output the acoustic waves to tissue grasped between jaw members 110 and 120. Although FIG. 3 depicts probes 140 in lower jaw member 120, the probes 140 may be disposed in upper jaw member 110 and/or lower jaw member 120. Probes 140 are electrically coupled to generator 500 and transmit the electrical signal (FIG. 5) thereto.

Generator 500 includes a phase/time reversal unit (PRU) 505. PRU 505 performs time reversal signal processing that is a technique for focusing waves. Time reversal signal processing is based upon a feature of wave equations known as reciprocity. Reciprocity says that if one has a solution to the wave equation, then the time reversal (using a negative time) of that solution is also a solution of the wave equation. This occurs because the standard wave equation only contains even order derivatives. Time reversal techniques can be modeled as a matched filter that is included in the PRU 505.

After probes 140 receive the acoustic signal from transducers 130, probes 140 transmit an electrical signal generated from the acoustic signal to the PRU 505. PRU 505 sends the reversed version (see FIG. 6) of the electrical signal of FIG. 5 to transducers 130 that transmit an acoustic signal back to probes 140 thereby, effectively autocorrelating the signal. Due to the principle of acoustical reciprocity, the reversed signal will be focused precisely in the same spot where it came from, i.e., probe 140. The resulting signal is concentrated in both time and space resulting in a signal that resembles a delta function as shown in FIG. 7. This precise focusing allows acoustic energy to be concentrated in a very small spot, thereby reducing thermal spread.

Using the inputs on generator 500, a clinician can select between sealing tissue grasped between jaw members 110 and 120 or cutting tissue between jaw members 110 and 120. A lower power setting may be used for sealing tissue while a higher power setting may be used to cut tissue. Using time reversal signal processing reduces the amount of energy needed (e.g., up to 5 times less energy) and eliminates the need for an amplifier, thereby reducing the components necessary in generator 500.

FIGS. 4A and 4B depicts different sealing surfaces for one of the jaw members of end effector assembly 105. As shown in FIG. 4A, sealing surface 410 includes a plurality of stop members 412 and piezoceramic transducers 414. Stop members 412 may provide a gap between jaw members 110 and 120 of end effector assembly 105 to effectively seal tissue. As shown in FIG. 4B, sealing surface 420 includes stop members 422 along the outer edges of sealing surface 420. Piezoceramic transducers 424 are disposed along the center of sealing surface 420. Transducers 414 and 424 may be formed beneath the sealing surfaces 410 and 420 respectively or be an integral part of sealing surface 410 and 420.

FIG. 4C depicts a top view of seal plate 430 according to another embodiment of the present disclosure. Seal plate 430 is made from stainless steel, and as described above, has piezoceramic transducers 432 disposed in locations 434 instead of stop members as shown in FIGS. 4A and 4B. Seal plate 430 may be formed by any suitable method. For instance, a layer of stainless steel may be provided and shaped to form seal plate 430. Then, a photolithography mask is applied to seal plate 430 leaving locations 434 exposed. An etching solution is applied to seal plate 430 to etch away exposed locations 434. Then the mask is removed leaving seal plate 430 with locations 434 etched away. When the jaw member is assembled, piezoceramic transducers 432 are placed in locations 434 of seal plate 430 and are coupled to generator 500.

The foregoing description is only illustrative of the present disclosure. Various alternatives and modifications can be devised by those skilled in the art without departing from the disclosure. Accordingly, the present disclosure is intended to embrace all such alternatives, modifications and variances. The embodiments described with reference to the attached drawing figures. are presented only to demonstrate certain examples of the disclosure. Other elements, steps, methods and techniques that are insubstantially different from those described above and/or in the appended claims are also intended to be within the scope of the disclosure. 

What is claimed is:
 1. An electrosurgical instrument, comprising: a housing having a plurality of transducers included therein; a waveguide coupled to and extending from the housing; and an end effector assembly disposed at a distal end of the waveguide including a pair of opposing jaw members, at least one of the jaw members including a probe, the probe configured to receive an acoustic signal from the plurality of transducers in the housing.
 2. The electrosurgical instrument according to claim 1, wherein the probe is coupled to a generator and the probe converts the received acoustic signal into an electrical signal that is transmitted to the generator.
 3. The electrosurgical instrument according to claim 2, wherein the generator receives the electrical signal and outputs a time-reversed signal to the plurality of transducers in the housing.
 4. The electrosurgical instrument according to claim 3, wherein the plurality of transducers in the housing transmits the time-reversed signal to the probe through the waveguide.
 5. The electrosurgical instrument according to claim 1, wherein the probe is a piezoceramic transducer.
 6. The electrosurgical instrument according to claim 1, wherein the probe is formed beneath a sealing surface of the at least one jaw member.
 7. The electrosurgical instrument according to claim 1, wherein the probe is formed as an integral part of a sealing surface of the at least one jaw member.
 8. The electrosurgical instrument according to claim 1, wherein the probe is formed as a stop member on top of a sealing surface of the at least one jaw member.
 9. An electrosurgical system comprising: an electrosurgical instrument including: a housing having a plurality of transducers included therein; a waveguide coupled to and extending from the housing; an end effector assembly disposed at a distal end of the waveguide including a pair of opposing jaw members, at least one of the jaw members including a transducer, the transducer configured to receive an acoustic signal from the plurality of transducers in the housing; and a generator coupled to the plurality of transducers in the housing and the transducer in the end effector assembly.
 10. The electrosurgical system according to claim 9, wherein the transducer in the end effector assembly converts the received acoustic signal from the plurality of transducers in the housing into an electrical signal that is transmitted to the generator.
 11. The electrosurgical system according to claim 10, wherein the generator includes a phase/time reversal unit configured to receive the electrical signal from the transducer in the end effector assembly and output a reversed electrical signal to the plurality of transducers in the housing.
 12. The electrosurgical instrument according to claim 9, wherein the transducer in the end effector assembly is a piezoceramic transducer.
 13. The electrosurgical instrument according to claim 9, wherein the transducer in the end effector assembly is formed beneath a sealing surface of the at least one jaw member.
 14. The electrosurgical instrument according to claim 9, wherein the transducer in the end effector assembly is formed as an integral part of a sealing surface of the at least one jaw member.
 15. The electrosurgical instrument according to claim 9, wherein the transducer in the end effector assembly is formed as a stop member on top of a sealing surface of the at least one jaw member.
 16. A method of providing energy to tissue comprising: providing an electrosurgical instrument having: a housing having a plurality of transducers included therein; a waveguide coupled to and extending from the housing; and an end effector assembly disposed at a distal end of the waveguide including a pair of opposing jaw members, at least one of the jaw members including a probe; generating an acoustic signal from the plurality of transducers; propagating the acoustic signal through the waveguide; receiving the acoustic signal at the probe; converting the acoustic signal to an electrical signal; transmitting the electrical signal to a generator; processing the electrical signal in the generator to generate a time-reversed signal; transmitting the time-reversed signal to the plurality of transducers; converting the time-reverse signal to a time-reversed acoustic signal; and transmitting the time-reversed acoustic signal to the probe. 